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Sequence of Operation

Chapter 4

750-177

4-7

FADM

Fresh Air Damper Motor

FADR

Fresh Air Damper Relay

Flame Detector

FDJB

Flame Detector Junction Box

FDPS

Flow Differential Pressure Switch

FFA

Flame Failure Alarm

FFL

Flame Failure Light

FFR

Flame Failure Relay

FGR

Flue Gas Recirculation

FGRCDTD

Flue Gas Recirculation Cool Down Time Delay

FGRCPS

Flue Gas Recirculation Cam Position Switch

FGRFM

Flue Gas Recirculation Fan Motor

FGRFMS

Flue Gas Recirculation Fan Motor Starter

FGRFMSI

Flue Gas Recirculation Fan Motor Starter Interlock

FGRMVLS

Flue Gas Recirculation Manual Valve Limit Switch

FGRTD

Flue Gas Recirculation Time Delay

FORS

First Out Reset Switch

FPM

Feed Pump Motor

FPMS

Feed Pump Motor Starter

FPR

Feed Pump Relay

FPS

Feed Pump Switch

FRI

Firing Rate Interface

FRP

Firing Rate Potentiometer (O2 Trim)

Flow Switch

FSS

Fuel Selector Switch

FSSM

Flame Signal Strength Meter

FVEL

Fuel Valve Energized Light

FVL

Fuel Valve Light

FVR

Fuel Valve Relay

FWC

Feed Water Control

FWVT

Feed Water Valve Transformer

Green (Color Of Pilot Light)

GGL

Gauge Glass Light

GOL

Gas Operation Light

GOR

Gas-Oil Relay

GOS

Gas-Oil Switch

GOR

Gas-Oil Relay

GPS

Gas Pressure Sensor

GPV

Gas Pilot Valve

GPVV

Gas Pilot Vent Valve

Gas Relay

GSSV

Gas Sensor Solenoid Valve

GVEL

Gas Valve Energized Light

GVTS

Gas Valve Test Switch

HATC

High Ambient Temperature Control

HBWTC

High Boiler Water Temperature Control

HBWTL

High Boiler Water Temperature Light

HFAV

High Fire Air Valve

HFGV

High Fire Gas Valve

HFL

High Fire Light

HFOV

High Fire Oil Valve

HFPS

High Furnace Pressure Switch

HFS

High Fire Switch

Table: 4-1 Electrical Nomenclature (Continued)

MNEMONIC

DESCRIPTION

HFS-A

High Fire Switch - Air

HGPL

High Gas Pressure Light

HGPR

High Gas Pressure Relay

HGPS

High Gas Pressure Switch

HHFL

Header High Fire Light

H/LWA

High Low Water Alarm

HLC

High Limit Control

HLFC

High-Low Fire Control

HLPC

High Limit Pressure Control

HLTC

High Limit Temperature Control

HMC

Header Modulating Control

HOPL

High Oil Pressure Light

HOPR

High Oil Pressure Relay

HOPS

High Oil Pressure Switch

HOLC

Header Operating Limit Control

HOTL

High Oil Temperature Light

HOTR

High Oil Temperature Relay

HOTS

High Oil Temperature Switch

HPCO

High Pressure Cutoff

HSPC

High Steam Pressure Control

HSPL

High Steam Pressure Light

HSPR

High Steam Pressure Relay

HSTC

High Stack Temperature Control

HSTL

High Stack Temperature Light

HSTS

High Stack Temperature Switch

HWAR

High Water Alarm Relay

HWC

High Water Control

HWCO

High Water Cutoff

HWL

High Water Light

(I.C.)

Instantaneously Closed

(I.O.)

Instantaneously Open

Ignition Light

INT

Interval (Timer)

Ignition Relay

Ignition Transformer

JPP

Jackshaft Position Potentiometer

LAMPS

Low Atomizing Media Pressure Switch

LASPS

Low Atomizing Steam Pressure Switch

LDL

Load Demand Light

LDPS

Low Differential Pressure Switch

LDS

Low Draft Switch

LFAV

Low Fire Air Valve

LFGV

Low Fire Gas Valve

LFHTD

Low Fire Hold Time Delay

LFL

Low Fire Light

LFOV

Low Fire Oil Valve

LFPS

Low Fire Pressure Switch

LFR

Low Fire Relay

LFS

Low Fire Switch

LFS-A

Low Fire Switch - Air

LFS-F

Low Fire Switch - Fuel

LFS-G

Low Fire Switch - Gas

LFS-O

Low Fire Switch - Oil

Table: 4-1 Electrical Nomenclature (Continued)

MNEMONIC

DESCRIPTION

Содержание FLX 1000

Страница 1: ...Manual Part No 750 177 R6 MODEL FLX PACKAGED BOILER 1 500 000 to 12 000 000 Btu hr Hot Water and Steam Fuel Light Oil Gas or Combination 5 2014...

Страница 2: ...nual 1 500 000 to 12 000 000 Btu hr Fuel Light Oil Gas or Combination Please direct purchase orders for replacement manuals to your local Cleaver Brooks authorized representative Manual Part No 750 17...

Страница 3: ...to show how a basic burner operates Operating controls will normally function for long periods of time and we have found that some operators become lax in their daily or monthly testing assuming that...

Страница 4: ...up and Operation 2 19 G Adjustments 2 26 H Gas System 2 34 I Oil System 2 37 J Combination Gas Oil System 2 39 K Modulation Control 2 40 L Air and Fuel Controls 2 42 M Maintenance 2 43 N Troubleshooti...

Страница 5: ...mit Pressure Control Steam 5 5 H High Limit Pressure Control Steam 5 5 I Modulating Temperature Control Hot Water 5 6 J Operating Limit Temperature Control Hot Water 5 6 K High Limit Temperature Contr...

Страница 6: ...F Oil Burner Maintenance 7 6 G Gas Burner Maintenance 7 7 H Refractory 7 7 I Casing Seals 7 7 Chapter 8 Parts Casing HW 8 2 Casing Low Pressure Steam 8 4 Casing High Pressure Steam 8 6 Steam Pressure...

Страница 7: ...inuous reliable operation If the boiler is to be used for temporary heat for example in new con struction properly treated water must be used Fail ure to do so can be detrimental to the boiler This ma...

Страница 8: ...20 F The operating pressure for hot water heating systems usually is 30 psig to 125 psig Steam and hot water boilers are defined according to design pressure and operating pressure Design pressure is...

Страница 9: ...al automatic switch is set on automatic 4 Low Water Cutoff and Pump Control Float operated control responds to the water level in the boiler It performs two distinct functions Stops firing of the burn...

Страница 10: ...F SAFETY VALVE SETTING TO STEAM 1 1 2 MIN Figure 2 3 Recommended piping for steam relief valve not furnished by Cleaver Brooks DANGER WARNING Only properly certified personnel such as the safety valve...

Страница 11: ...a vertical position so that discharge piping and code required drains can be properly piped to prevent buildup of back pressure and accumulation of foreign material around the valve seat area Apply on...

Страница 12: ...Chapter 1 General Description 1 6 750 177...

Страница 13: ...e the Canadian Gas Association CGA B149 and the Canadian Standards Association CSA B140 codes shall prevail Other regulatory agency control options are available DANGER CAUTION ONLY FACTORY AUTHORIZED...

Страница 14: ...hutdown This safety control also includes flame detection system to confirm proper operation or cause a manual reset lockout in the event of a pilot or main flame failure External controls connected t...

Страница 15: ...enings in boiler room Two 2 permanent air supply openings in the outer walls of the boiler room are rec ommended Locate one 1 at each end of the boiler room preferably 7 foot or lower This allows air...

Страница 16: ...to provide the burner s high fire rate rated gallons per hour gph Smaller gph nozzles may be used to match burner output to a heat exchanger s required input Models V13 34 are supplied with simplex no...

Страница 17: ...oil spray contacts the established gas pilot flame On full modulation units the modulating actuator varies the oil metering valve setting The metering valve located in the return oil loop reduces the...

Страница 18: ...r 2 Profire V Burner 2 6 750 177 Figure 2 3 Full Modulation Oil System with Integral Pump Return Flow Nozzle V13 55 OIL NOZZLE OIL PRESSURE SWITCH N C VALVES FUEL UNIT PRESSURE TAP MODULATING MOTOR OI...

Страница 19: ...ssure to specified pressure required at the burner manifold Input is set by main gas pressure regulator adjustment Main Gas Cocks Used for manual shutoff of the gas supply upstream of the pressure reg...

Страница 20: ...Chapter 2 Profire V Burner 2 8 750 177 Figure 2 5 Typical Gas Train for Full Modulation System V13 34 Figure 2 6 Typical Gas Train for LHO LHL Systems V35 63 Full Modulation Systems V35 168...

Страница 21: ...air is supplied by the burner forced draft blower providing adequate air for any normal combustion condition Since draft control is essential to maximum efficiency a draft regulator maybe required whe...

Страница 22: ...l and vertical 3 Read up from line total feet of copper tube to the intersection line of the specific suction capacity in gph 4 Read left to column inches of vacuum at fuel unit This is vacuum require...

Страница 23: ...Profire V Burner Chapter 2 750 177 2 11 Figure 2 8 Typical No 2 Oil Loop Single Burner Figure 2 9 Multiple Burners with Separate Suction Lines...

Страница 24: ...Chapter 2 Profire V Burner 2 12 750 177 Figure 2 10 Typical Oil Loop for Multiple Burners with Transfer Pump Figure 2 11 Typical Installation Using Day Tank...

Страница 25: ...rain components upstream of the butterfly valve are shipped loose These components should be mounted by the installer as close to the butterfly valve as practical If a pre piped and wired gas train is...

Страница 26: ...otected with refractory The burner mounting flange must be properly sealed against the vessel front plate 6 Make certain that the operator in charge is properly instructed in operation and maintenance...

Страница 27: ...open To prevent a surge the primary gas valve opens at a slowed rate Gas flow to the manifold is metered based on the butterfly valves low fire setting Safety shut off valves open allowing oil to flow...

Страница 28: ...up Valves open To prevent a surge the primary gas valve opens at a slowed rate Gas flow to the manifold is metered based on the butterfly valves low fire setting Safety shut off valves open allowing o...

Страница 29: ...butterfly valve low fire setting Safety shut off valves open allowing oil to flow from pump to nozzle Oil pressure at the nozzle is based on the pump s pressure setting less the volume of oil returnin...

Страница 30: ...RUN MODULATE Damper is driven by its parallel positioning actuator to a firing rate position as determined by the parallel positioning control The actuator and parallel positioning control will then c...

Страница 31: ...he wiring diagram and local codes The control cabinet components are 120 volt If a control transformer is supplied ensure that the supply voltage matches its primary voltage Check motor rotation by mo...

Страница 32: ...the suction line a closed valved kinked copper tubing plugged filter sticking check valve frozen oil line undersized oil line or excessive lift When there is a positive head of oil at the fuel unit ei...

Страница 33: ...ll in Upon completion of successful test disconnect power supply Reconnect oil safety shutoff valve and turn on manual pilot gas valve Reconnect power supply and proceed with startup procedures BURNER...

Страница 34: ...e manual oil valves 3 When firing on gas open the main manual gas valve 4 When firing on gas manually reset the high and low gas pressure switches if applicable 5 Place the gas oil selector switch if...

Страница 35: ...prior to putting the equipment back into service DANGER WARNING FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT IN EXPLOSION FIRE PROPERTY DAMAGE AND PERSONAL INJURY THIS PROCEDURE MUST BE PERFORMED ONLY...

Страница 36: ...Do not disturb established low fire adjustment Allow the burner to return to low fire position before adjusting high or intermediate setting CO levels should be less than 400 ppm on an air free basis...

Страница 37: ...CULATION AT ALL TIMES TO AVOID DAMAGE AND SEIZURE OF THE PUMP NORMAL OPERATION Normal operation must be with the MANUAL AUTO switch selector on AUTO In automatic operation the operating cycle always p...

Страница 38: ...t may help in making preliminary settings The proper settings of air fuel ratios must be determined by flue gas analysis Combustion gas analysis indicates the air to fuel ratio and the degree of compl...

Страница 39: ...usting the pressure setting of the pilot regulator Normal setting is 4 to 6 W C when the pilot is burning The flame must be sufficient to be proven by the flame detector and ignite the main flame To a...

Страница 40: ...djustment 1 Lock out and tag the electrical power supply to the burner to prevent inadvertent operation during checkout or maintenance activities 2 Disconnect the high voltage power supply from the oi...

Страница 41: ...Carefully install the drawer assembly into the burner 5 Re connect the oil line and high voltage power cable to the assembly Measure the position of the diffuser to the air baffle and compare to the f...

Страница 42: ...LE TIP TO BOTTOM EDGE OF ELECTRODE WIRES 5 32 BETWEEN INNER EDGES OF ELECTRODE WIRES 656 10215 000 Chapter 2 Profire V Burner 2 30 750 177 Figure 2 16 Drawer Assembly for VL Oil Only V13 34 Watertube...

Страница 43: ...F DIFFUSER 1 89 REAR FACE OF DIFFUSER TO FRONT FACE OF 25 NOZZLE TIP TO OUTER EDGE OF ELECTRODE WIRES 7 16 FROM CENTER OF OIL NOZZLE TIP TO BOTTOM EDGE OF ELECTRODE WIRES 5 32 BETWEEN INNER EDGES OF E...

Страница 44: ...REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656 10214 000 Figure 2 21 Drawer Assembly for VG Gas Only V60 110 Watertube 1 83 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 00 FROM NOZZLE TIP...

Страница 45: ...re V Burner Chapter 2 750 177 2 33 Figure 2 23 Drawer Assembly for VG Gas Only V120 168 Watertube 1 92 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 00 FROM NOZZLE TIP TO FRONT FACE OF DIFFUSER 65...

Страница 46: ...is the pressure that is required to fire the burner at its rated capacity The gas pressure regulator must be adjusted to achieve this pressure to assure full input LOW GAS PRESSURE SWITCH Turn adjusti...

Страница 47: ...gas butterfly valve low and high gas pressure switches and an air damper assembly The auxiliary switch inside the M436 Mod motor makes or breaks the high fire gas The Low High Low boiler control energ...

Страница 48: ...e in the low fire position 6 After a few seconds the O2 analyzer should have an accurate reading of the O2 present in the flue gas Normally O2 levels are set between 4 to 6 at low fire for standard tu...

Страница 49: ...ing is complete continue with the instructions above adjusting the cam at each screw to obtain the proper NOx values Verify the values modulating back to low fire and adjust accordingly I Oil System A...

Страница 50: ...r for a clean fire Record the combustion reading from the flue gas analyzer normally 3 5 to 4 5 O2 and less than No 1 smoke Bacharach To adjust the oil pressure regulating valve remove the lockscrew a...

Страница 51: ...ttings Complete the Startup Report 10 Turn the MANUAL AUTO switch to AUTO The burner will now modulate according to the load demand to the boiler J Combination Gas Oil System In general the combinatio...

Страница 52: ...oil metering unit When properly adjusted coordinated movement of the air and fuel control devices provide proper fuel air ratios through the firing range In linkage adjustments several important facto...

Страница 53: ...en operate the automatic modulating cycle to assure satisfactory results Tighten the locking setscrews NOTE It is essential that the cam spring cam follower bearing wheel and cam follower arm at the p...

Страница 54: ...djustments also vary with specific system applications Turndown capability for oil is less than that of natural gas On combination fueled burners gas turndown performance may be restricted by the exce...

Страница 55: ...TEM Most operating controls require very little maintenance beyond regular inspection Examine electrical connections Keep the controls clean Remove any dust from the interior of the control Covers sho...

Страница 56: ...ler blade and using it as a lever will only damage the blade FIRING HEAD INSPECTION Open side access panels to view the drawer assembly Inspect the lead wire to the ignition electrode It must be firml...

Страница 57: ...st if necessary For burners equipped with a gas pilot the pilot is located on the side opposite to the main gas entrance 1 Close the gas pilot cock 2 Disconnect the pilot gas supply line 3 Remove the...

Страница 58: ...with a scribed or pencil line where the three mounting screws are located to insure that the diffuser is placed back in the same position 3 Remove the screws holding the diffuser to the blast tube an...

Страница 59: ...actuator if valve fails to operate After replacement cycle the valve with the fuel shut off to determine that it opens and closes If the valve has a visual indicator observe its position for correct o...

Страница 60: ...ner fuel supply to extinguish main flame 2 The fuel valves will be de energized and the relay will signal the condition within four seconds Thecontrol will then lock out on a safety shutdown 3 The fla...

Страница 61: ...or fluctuating Linkages Operator Check all burner linkages for tightness Tighten if required MONTHLY Low Fan Pressure Interlock Operator Manually adjust until switch opens High and Low Gas Pressure In...

Страница 62: ...3 Limit circuit not completed no voltage at end of limit circuit program relay termi nal a Pressure or temperature is above setting of operation control b Water below required level Low water light an...

Страница 63: ...med or linkage binding 4 Running interlock circuit not completed a Combustion proving switches defective or not properly set b Motor starter interlock contact not closed 5 Flame detector defective sig...

Страница 64: ...ogrammer lockout switch has not tripped check the limit circuit for an opened safety control 6 If the programmer lockout switch has tripped a Check fuel lines and valves b Check flame detector c Check...

Страница 65: ...LX Burner Characteristics Model No Burner Maximum Input MBH Burner Model Fan Motor 3450 RPM Voltage FLX 150 1500 PFVLG 15 115 230 1 60 FLX 200 2000 PFVLG 20 115 230 1 60 FLX 250 2500 PFVLG 25 115 230...

Страница 66: ...4 21 7 PFVG 20 FLX 250 1 5 12 4 15 7 PFVG 25 FLX 300 1 5 15 9 20 7 PFVG 30 FLX 350 1 5 15 5 22 0 PFVG 35 FLX 400 1 5 18 7 27 2 PFVG 40 FLX 450 2 16 0 26 7 PFVG 45 FLX 500 2 17 6 21 0 PFVG 50 FLX 550 2...

Страница 67: ...High Water Cut Off Operating Limit High Limit Operating Control Stack Temp Interlock Flame Failure Combustion Air Switch High Purge Switch Low Fire Interlock Oil Pressure Switch Oil Valve with P O C I...

Страница 68: ...Chapter 2 Profire V Burner 2 56 750 177...

Страница 69: ...severe stress to the pressure vessel Figure 3 1 Upper Drum Hot Water A B C C A HOT WATER OUTLET B AIR VENT TAPPING C PRESSURE TEMPERATURE GAUGES Although it is of prime importance the subject of wate...

Страница 70: ...7 111 5 0 11 89 2 FLX 600 2 99 486 8 0 77 243 4 0 35 162 3 0 20 121 7 0 13 97 4 FLX 700 1 75 567 9 0 45 284 0 0 21 189 3 0 12 142 0 0 08 113 6 FLX 800 2 27 649 1 0 59 324 5 0 27 216 4 0 15 162 3 0 10...

Страница 71: ...The recommended minimum system return water temperature shall be 140 F 60 C when firing natural gas or 150 F 66 C when firing oil And for special burner applications firing digester gas minimum return...

Страница 72: ...en changes in firing rate or operating pressure of the boiler will initiate a call for water from the make up controller which will require that the feed water be delivered to the boiler in sufficient...

Страница 73: ...column Figure 3 4 Blowdown is the removal of some of the concentrated water from the boiler and the water level control system in order to lower the concentration of solids in the water Solids are int...

Страница 74: ...pen the downstream valve slightly to release the water trapped between the valves then close the valve again The water column and gauge glass should be blown down by draining until the water in the ga...

Страница 75: ...erformed 3 months after the initial start up then at regular 6 9 or 12 month intervals thereafter The frequency of periodic inspections will depend upon the internal conditions found the particular in...

Страница 76: ...m It is important that the water used for the filling process is at a temperature of 70 F or above 7 Add the boilout solution using a chemical pump DANGER WARNING The chemicals used in this procedure...

Страница 77: ...oiler layup procedures in this chapter H Washing Out Depending on system integrity feedwater quality or operating conditions the water side of the boiler may need to be washed out on occasion In theor...

Страница 78: ...or internal or external corrosion or leakage Fireside surfaces also should be cleaned so that metal surfaces welds joints tube fittings and any previous repairs can be readily checked DANGER WARNING T...

Страница 79: ...orage wet or dry Your local Cleaver Brooks authorized representative can recommend the better method based on the circumstances of your particular installation Regardless of the method employed the bo...

Страница 80: ...er will be out of service for shorter periods of time when a boiler is held in standby conditions or in cases where dry storage is not practical The boiler held in wet storage can be brought back into...

Страница 81: ...nclature to aid in applying the text to the wiring diagram The burner and control system are in starting condition when the following conditions exist Boiler water is up to the correct level closing t...

Страница 82: ...ssures switch LGPS High gas pressure switch HGPS Fuel valve interlock circuit Main gas valve auxiliary switch MGVAS Oil valve auxiliary switch OVAS Blower Motor Starter Circuit Blower motor starter BM...

Страница 83: ...nto the running interlock circuit must be closed within 10 seconds after the start sequence In the event any of the controls are not closed at this time or if they subsequently open the program relay...

Страница 84: ...ire firing range When a shutdown occurs while operating in the manual position at other than low fire the damper will not be in a closed position thus allowing more air than desired to flow through th...

Страница 85: ...curs during normal operation and or the flame is no longer sensed by the detector the flame relay will trip within 2 to 4 seconds to deenergize the fuel valve circuit and shut off the fuel flow The re...

Страница 86: ...R Blower Motor Power Relay BMPS Blower Motor Purge Switch BMR Blower Motor Relay BMS Blower Motor Starter BMSI Blower Motor Starter Interlock BMSS Boiler Master Selector Switch BS Burner Switch BSS Bo...

Страница 87: ...e Light HFOV High Fire Oil Valve HFPS High Furnace Pressure Switch HFS High Fire Switch Table 4 1 Electrical Nomenclature Continued MNEMONIC DESCRIPTION HFS A High Fire Switch Air HGPL High Gas Pressu...

Страница 88: ...lve Auxiliary Switch MOVEL Main Oil Valve Energized Light MPC Modulating Pressure Control MPCB Main Power Circuit Breaker MPP Manual Positioning Potentiometer Table 4 1 Electrical Nomenclature Continu...

Страница 89: ...wer Pressure Switch SBR Sootblower Relay SC Scanner SCTS Supervisory Cock Test Switch SDL Steam Demand Light SHT Steam Heater Thermostat SHV Steam Heater Valve SLCL Safety Limits Complete Light SPIR S...

Страница 90: ...Chapter 4 Sequence of Operation 4 10 750 177...

Страница 91: ...10 T Fuel Oil Combustion Adjustment 5 12 U Low Oil Pressure Switch 5 12 A GENERAL Each Cleaver Brooks boiler is tested for correct operation before shipment from the factory However variable conditio...

Страница 92: ...ver Brooks Service or Parts representative it may have an incorrect stroke To prevent damage verify the 90 stroke prior to installing a replacement The stroke may be determined by powering the motor a...

Страница 93: ...imit control modulating control and the high limit control The burner will be on whenever the pressure or temperature is less than point B and off whenever pressure or temperature is greater than poin...

Страница 94: ...r in low fire The modulating control will be calling for high fire and the burner will move to that position as rapidly as the damper motor can complete its travel Note Rapid heat input can subject th...

Страница 95: ...he fixed time required for proving the pilot and main flame In addition approximately one half minute is required for the damper motor to travel from low to high fire The time lag may allow pressure o...

Страница 96: ...ciently above the operating limit temperature to avoid unnecessary shutdowns The control requires manual resetting after tripping on a temperature increase To reset allow the water temperature to drop...

Страница 97: ...ot only the quantity of gas demanded by the unit but must also be at a pressure high enough to overcome the pressure loss due to the frictional resistance imposed by the burner system and the control...

Страница 98: ...e a warm boiler adjustments should be made to obtain efficient combustion Burner efficiency is measured by the amount or percentage of O2 present in the flue gas O2 readings determine the total amount...

Страница 99: ...the shaft Determine the actual gas flow from a meter reading See Section O With the butterfly valve open and with regulated gas pressure set at the calculated pressure the actual flow rate should be...

Страница 100: ...casionally require adjustments to assure highest combustion efficiency The handling and burning characteristics may vary from one delivery of oil to another Therefore it is recommended that the oil sy...

Страница 101: ...FVG 45 FLX 500 2 17 6 21 0 PFVG 50 FLX 550 2 22 9 27 1 PFVG 55 FLX 600 2 20 0 24 9 PFVG 60 FLX 700 2 25 2 31 9 PFVG 70 FLX 800 2 5 19 9 22 2 PFVG 80 FLX 900 2 5 24 7 27 7 PFVG 90 FLX 1000 2 5 31 6 31...

Страница 102: ...nalyzers but may be displayed as a calculation The O2 levels through the entire firing range of the burner low fire to high fire should be tested Cleaver Brooks recommendations on turndown should also...

Страница 103: ...IR 10 20 30 40 50 60 5 6 7 8 9 10 11 12 1 1 2 2 3 3 4 4 5 5 6 6 7 8 9 0 PER CENT CO 2 IN FLUE GAS FIRST VISIBLE TRACE OF STACK HAZE 1 10 of 1 CO 1 000 PPM 15 Figure 5 4 Flue Gas Analysis Chart for Nat...

Страница 104: ...Chapter 5 Adjustment Procedures 5 14 750 177...

Страница 105: ...perly the trouble shooting chapter should be referred to for assistance in pinpointing problems that may not be readily apparent The program relay has the capability to self diagnose and to display a...

Страница 106: ...ches 4 Fuel valve interlock circuit not completed A Fuel valve auxiliary switch not enclosed NO IGNITION 1 Lack of spark A Electrode grounded or porcelain cracked B Improper electrode setting C Loose...

Страница 107: ...re above modulating control setting 2 Manual automatic switch in wrong position 3 Inoperative modulating motor 4 Defective modulating control 5 Binding or loose linkage setscrews etc SHUTDOWN OCCURS D...

Страница 108: ...wn A Motor defective B Loose electrical connection C Damper motor transformer defective 4 Motor does not operate on demand A Manual automatic switch in wrong position B Modulating control improperly s...

Страница 109: ...ld system startup A Any time a boiler is started with a cold system it will produce condensate until internal surface temperatures exceed 130 F Internal condensation will not be produced once a boiler...

Страница 110: ...Chapter 6 Troubleshooting 6 6 750 177...

Страница 111: ...uld result in electrical shock serious personal injury or death Good housekeeping practices help maintain a professional appearing boiler room Only trained and authorized personnel should be permitted...

Страница 112: ...te to many years of reliable performance from the equipment Cleaver Brooks offers a Planned Maintenance Program that covers many of the items included on this chapter For more information on the Plann...

Страница 113: ...3rd pass is only open on the ends cleaning is done by pushing a wire brush mounted on a long handle through from each end Since the arc of movement is restricted cleaning the 3rd pass must be done fr...

Страница 114: ...bottom section into the boiler and allowing it to slide down to catch the bottom clamp angle Then slide the end panels under the corner frames and install any remaining center panels The fireside shou...

Страница 115: ...tional feedwater treatment that might not otherwise be necessary To verify the proper operation of float style low water cutoff devices the system must be drained Remove the operating mechanism from t...

Страница 116: ...of the feedwater controller and the low water cutoffs DANGER CAUTION If a control does not break the circuit to stop the burner at the proper point then shut down the burn er immediately Failure to do...

Страница 117: ...ntrol be kept on hand and service be rotated between the active and the spare control programmer Note Be sure that the connecting contacts on the control and the base are not bent out of position DANG...

Страница 118: ...y or death Reassemble the strainer taking care to seal the canister properly to avoid air infiltration and resulting loss of suction Open the fuel supply and the return line valves G Gas Burner Mainte...

Страница 119: ...igh temperature bonding air dry mortar such as Cleaver Brooks Corline DANGER WARNING Disconnect main power to the boiler and the pilot fuel supply to the burner before the burner door is opened Electr...

Страница 120: ...o set up and apply a thick bead of high temperature silicone around the drum and install the cover plates Sight Port Inspect the area around the sight port for paint discoloration A hot spot around th...

Страница 121: ...er 8 2 Flextube Casing Low Pressure Steam 8 4 Flextube Casing High Pressure Steam 8 6 Steam Pressure Controls 8 8 Water Level Controls 8 9 Water Column Main and Aux 15 Steam 8 11 Water Column Main and...

Страница 122: ...8 2 750 177 Figure 8 1 Typical Hot Water Flextube Casing...

Страница 123: ...6 26 868 1506 28 868 1506 60 868 1506 96 868 1506 128 18 Capscrew hex hd 1 2 13x 1 1 2 lg 868 102 8 868 102 8 868 102 8 868 102 8 868 102 8 19 Capscrew hex hd 5 8 11x 1 1 2 lg 868 188 8 868 188 8 868...

Страница 124: ...8 4 750 177 Figure 8 2 Typical Low Pressure Steam Flextube Casing...

Страница 125: ...868 102 8 868 102 8 868 102 8 868 102 8 868 102 8 19 Capscrew hex hd 5 8 11x 1 1 2 lg 868 188 8 868 188 8 868 188 8 868 188 8 868 188 8 20 Screw self tapping x 1 lg 841 423 56 841 423 56 841 423 56 8...

Страница 126: ...8 6 750 177 Figure 8 3 Typical High Pressure Steam Flextube Casing...

Страница 127: ...8 102 8 868 102 8 868 102 8 868 102 8 868 102 8 19 Capscrew hex hd 5 8 11x 1 1 2 lg 868 188 8 868 188 8 868 188 8 868 188 8 868 188 8 20 Screw self tapping x 1 lg 841 423 50 841 423 56 841 423 56 841...

Страница 128: ...Parts Chapter 8 8 8 750 177 Steam Pressure Controls...

Страница 129: ...Chapter 8 Parts 750 177 8 9 Water Level Controls...

Страница 130: ...Parts Chapter 8 8 10 750 177 Water Level Controls continued...

Страница 131: ...Chapter 8 Parts 750 177 8 11 Water Column Main and Aux 15 Steam...

Страница 132: ...Parts Chapter 8 8 12 750 177 Water Column Main and Aux 150 Steam...

Страница 133: ...Chapter 8 Parts 750 177 8 13 Safety Valves...

Страница 134: ...Parts Chapter 8 8 14 750 177...

Страница 135: ......

Страница 136: ...e mail info cleaverbrooks com Web Address http www cleaverbrooks com...

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